Thermal/Fluid Characteristics of 3-D Woven Mesh Structures as Heat Exchanger Surfaces

The present work demonstrates the fabrication methodology of a three-dimensional (3-D), aluminum wire filament, bonded mesh deployed as a heat exchange surface. A model of the effective thermal conductivity of the mesh is developed. Apparatus to measure the coolant pressure-drop and heat transfer coefficient are described. Measurements are reported for fabricated test samples of varying thickness. Mesh Stanton number and friction factor correlations for a coolant with Prandtl number equal to 9.5 (chilled water) are reported. A heat exchanger performance evaluation, comparing the 3-D woven mesh technology to another exchanger surface technology, is described. We have found that the weaving/wire bonding process must be carefully controlled to insure that target porosity, specific surface area and effective thermal conductivity are achieved. Effective thermal conductivities are found to be at least two-times larger than achieved in other comparable porous media configurations. Mesh friction factor and Stanton number are comparable to those achieved with other exchanger surface technologies. The exchanger performance comparison shows that exchangers having superior performance can be configured.